JP2004001221A - Polishing supply with structure - Google Patents
Polishing supply with structure Download PDFInfo
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- JP2004001221A JP2004001221A JP2003173709A JP2003173709A JP2004001221A JP 2004001221 A JP2004001221 A JP 2004001221A JP 2003173709 A JP2003173709 A JP 2003173709A JP 2003173709 A JP2003173709 A JP 2003173709A JP 2004001221 A JP2004001221 A JP 2004001221A
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- Prior art keywords
- article
- binder
- abrasive
- composite
- abrasive article
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Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
- B24D11/00—Constructional features of flexible abrasive materials; Special features in the manufacture of such materials
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
- B24D3/00—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents
- B24D3/001—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as supporting member
- B24D3/002—Flexible supporting members, e.g. paper, woven, plastic materials
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
- B24D3/00—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents
- B24D3/02—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent
- B24D3/20—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent and being essentially organic
- B24D3/28—Resins or natural or synthetic macromolecular compounds
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Polishing Bodies And Polishing Tools (AREA)
Abstract
Description
【0001】
【発明の属する技術分野】
本発明は接着されたコンポジット研摩材を有する裏材料を有する研摩用品に関する。
【0002】
【従来の技術】
研摩用品、特に細かいグレードの用品に伴う2種の主要な問題は、ローディングおよび製品の持続性である。ローディングは、研摩グレイン間の空間が削りくず(すなわち、研摩されているワークピースから除去された材料)で満たされ、それが盛り上がることにより引き起こされる問題である。たとえば、木材にヤスリがけする場合は、オガクズの粒子が研摩グレインの間に止どまり、そのことにより研摩グレインのカット能力が低下し、木材ワークピースの表面の焼けの可能性が生じる。
【0003】
米国特許第2252683号(アルバートソン)(特許文献1)には、裏材料および樹脂状接着剤により裏材料に接合された複数の研摩グレインを有する研摩材が開示されている。製造中において、樹脂状接着剤が硬化される前には、研摩用品はパターンを有する加熱されたモールド中に位置させられる。逆のパターンが裏材料に転写される。
【0004】
米国特許第2292261号(アルバートソン)(特許文献2)には、その上に研摩被覆を有する繊維状裏材料を有する研摩用品が開示されている。研摩被覆はバインダー中に埋め込まれた研摩粒子を有する。バインダーが硬化されない場合は、研摩被覆は複数のリッジ(ridges)を有する圧力ダイで処理される。このことにより、垂直および水平方向に矩形溝がエンボスされた研摩被覆となる。
【0005】
米国特許第3246430号(ハースト)(特許文献3)には、熱可塑性接着剤で含浸された繊維状裏材料を有する研摩用品が開示されている。この裏材料が連続リッジパターンで処理された後に、接合系および研摩グレインが設けられる。このことにより、研摩グレインの高および低リッジを有する研摩用品が得られる。
【0006】
米国特許第4539017号(オーガスチン)(特許文献4)には、裏材料、裏材料上のエラストマー性材料の支持層、および支持層に接着された研摩被覆を有する研摩用品が開示されている。研摩被覆はバインダーにわたって分散された研摩グレインからなる。さらに、研摩被覆はパターンの形状となりうる。
【0007】
米国特許第4773920号(チャスマンら)(特許文献5)には、フリーラジカル硬化性バインダーにわたって分散された研摩グレインから形成された研摩コンポジットを有する研摩ラッピング(lapping)用品が記載されている。また、この特許はこの研摩コンポジットはロトグラビアロールによりパターンに形成しうることを開示している。
【0008】
上述の特許により製造された研摩用品のいくつかは耐ローディング性および製造に安価であるけれども、これらは高レベルの持続性に欠ける。研摩用品が従来の方法で作製される場合は、接着剤またはバインダー系は硬化前または硬化中に流動し得、そのことにより、製品の持続性に悪影響を与える。
【0009】
高レベルの持続性を有する、ローディング耐性でありかつ安価な研摩用品が望まれている。
【0010】
【特許文献1】
米国特許第2252683号明細書
【特許文献2】
米国特許第2292261号明細書
【特許文献3】
米国特許第3246430号明細書
【特許文献4】
米国特許第4539017号明細書
【特許文献5】
米国特許第4773920号明細書
【0011】
【発明の要旨】
本発明は構造を有する研摩用品、およびこのような用品を調製する方法を提供する。
【0012】
一局面では、本発明は、少なくとも一主要表面上に、バインダー中に分散された複数の研摩グレインを有する研摩コンポジットを支持する裏材料を有する被覆研摩用品を包含する。バインダーは研摩グレインを分散するための媒体として機能し、これは裏材料に研摩コンポジットを接合する。研摩コンポジットは、たとえば、ピラミッド状のような予め定められた形状を有する。使用前には、個々の研摩グレインが予め定められた形状の面を越えて突出しないことが好ましい。与えられた形状の寸法は実質的に均一とされうる。さらに、コンポジットは予め定められた配列で配置される。この予め定められた配列は一定の繰り返しを示しうる。予め定められた配列の繰り返しパターンはリニア形状またはマトリックスの形状でありうる。
【0013】
他の局面では、本発明は、照射硬化性バインダー中に分散された複数の研摩グレインを有する研摩コンポジットを少なくとも一主要表面上に支持する裏材料を有する被覆研摩用品を包含する。この研摩コンポジットは予め定められた配列で配置された予め定められた形状を有する。
【0014】
研摩コンポジットの正しい特性は、高レベルの持続性を有する研摩用品を提供する。さらに、この持続性は優れた性能を提供する。
【0015】
さらに他の局面では、本発明は以下の工程を包含する。被覆研摩用品の作製方法を提供する。
(1)バインダーと複数の研摩グレインとの混合物を含むスラリーを製造用具上に導入する工程;
(2)裏材料の片側の主要表面をスラリーが濡らすように製造用具の外側表面に裏材料を導入することにより、中間用品を形成する工程;
(3)上記中間用品が製造用具の外側表面から分離する前にバインダーを少なくとも部分的に硬化またはゲル化させることにより、被覆研摩用品を形成する工程;および
(4)上記被覆研摩用品を製造用具から除去する工程。
【0016】
この4工程は連続的に行うことが好ましく、そのことが被覆研摩用品の効率的な作製方法を提供する。いずれかの製造法の実施態様において、スラリーが製造用具に導入された後に、スラリーは硬化またはゲル化の前に認められる流動を示さない。
【0017】
さらに他の局面では、本発明は、以下の工程を包含する被覆研摩用品を作製する方法を提供する。
(1)バインダーと複数の研摩グレインとの混合物を含むスラリーを、このスラリーが裏材料の前側を濡らすように裏材料上に導入することにより、中間用品を形成する工程;
(2)外側表面を有する製造用具に上記中間用品を導入する工程;
(3)中間用品が製造用具の外側表面から分離する前に少なくとも部分的にバインダーを硬化またはゲル化させることにより、被覆研磨用品を形成する工程;および
(4)上記製造用具から被覆研摩用品を除去する工程。
【0018】
この4工程は連続的に行うことが望ましく、そのことが被覆研摩用品を作製するための効率的な方法を提供する。いずれかの製造法の実施態様において、スラリーが製造用具に導入された後に、このスラリーは硬化またはゲル化前に認められる流動を示さない。
【0019】
【詳細な説明】
本発明は構造を有する研摩用品およびこのような用品を作製する方法を提供する。ここで用いる「構造を有する研摩用品」と言う用語は、バインダー中に分散された研摩グレインを有するコンポジットが予め定められた形状を有し、これらが予め定められた配列で配置されている研摩用品を意味する。
【0020】
図1において、被覆研摩用品10は一主要表面上に研摩コンポジット14を支持する裏材料12を有する。研摩コンポジットはバインダー18中に分散された複数の研摩グレイン16を有する。この特定の実施態様において、バインダーは研摩コンポジット14を裏材料12に接合する。研摩コンポジットは視認できる形状を有する。被覆研摩用品が使用される前にその形状の平面を越えて突出していない研摩グレインを用いることが好ましい。表面を研摩するために被覆研摩用品が用いられるにつれて、このコンポジットは分解し、未使用の研摩グレインが現れる。
【0021】
本発明の裏材料に好ましい材料には、ポリマーフィルム、紙、布、金属フィルム、バルカンファイバー、不織基材、これらの組み合わせおよびこれらの処理品が含まれる。裏材料は、ポリエステルフィルムのようなポリマーフィルムであることが好ましい。いくつかの場合に、裏材料は紫外線照射に対して透明であることが望ましい。また、フィルムは、研摩コンポジットの裏材料に対する接着を促進するためにポリエチレンアクリル酸のような材料で下塗りすることが好ましい。
【0022】
被覆研摩用品を形成した後に、裏材料は他の基材にラミネートされうる。たとえば、裏材料は、金属板のようなより堅いより剛性の基材にラミネートされることにより、剛性支持体上に支持された正確な研摩コンポジットを有する被覆研摩用品が提供される。
【0023】
研摩コンポジットを有さない裏材料の表面は感圧接着剤またはフックおよびループ型取り付け装置を有し得、そのことにより、この研摩用品はバックアップパッドに固定されうる。この目的に適する感圧接着剤の例には、ゴムベースの接着剤、アクリレートベースの接着剤およびシリコーンベースの接着剤が含まれる。
【0024】
研摩コンポジットは、未硬化または未ゲル化バインダー中に分散された複数の研摩グレインを含有するスラリーから形成される。硬化またはゲル化において、研摩コンポジットは固形化、すなわち予め定められた形状および予め定められた配列に固定される。
【0025】
研摩グレインのサイズは約0.5〜約1000μm、好ましくは約1〜約100μmの範囲でありうる。しばしば、狭い粒子サイズの分散は、研摩されるワークピースにより細かい仕上げを提供しうる研摩用品を提供する。本発明に適する研摩グレインの例には、溶融酸化アルミニウム、熱処理酸化アルミニウム、セラミック酸化アルミニウム、シリコンカーバイド、アルミナジルコニア、ガーネット、ダイヤモンド、立方体窒化ボロン、およびこれらの混合物が含まれる。
【0026】
バインダーはその中に研摩グレインが分散されうる媒体を提供する必要がある。好ましくは、このバインダーは比較的迅速に硬化またはゲル化することにより研摩用品を素早く製造可能とする。比較的速くゲル化するけれども、完全硬化するのにより長時間を要するバインダーもある。ゲル化は、硬化が始まるまでコンポジットの形状を維持する。速く硬化するか、または速くゲル化するバインダーにより高い持続性の研摩コンポジットを有する被覆研摩用品が得られる。本発明に好ましいバインダーの例には、フェノール樹脂、アミノプラスト樹脂、ウレタン樹脂、エポキシ樹脂、アクリレート樹脂、アクリレート化イソシアヌレート樹脂、尿素−ホルムアルデヒド樹脂、イソシアヌレート樹脂、アクリレート化ウレタン樹脂、アクリレート化エポキシ樹脂、グルーおよびこれらの混合物が含まれる。バインダーは熱可塑性樹脂でもよい。
【0027】
用いられるバインダーに依存して、熱、赤外線、電子線、紫外線照射または可視光照射のようなエネルギー源により硬化またはゲル化を行いうる。
【0028】
上述のように、バインダーは照射硬化性であるうる。照射硬化性バインダーは照射エネルギーにより少なくとも部分的に硬化されるか、または少なくとも部分的に重合されうるいずれかのバインダーである。典型的には、これらのバインダーはフリーラジカル機構により重合される。好ましくは、これらは、アクリレート化ウレタン、アクリレート化エポキシ、垂れ下がったα,β−不飽和カルボニル基を有するアミノプラスト誘導体、エチレン性不飽和化合物、少なくとも1個の垂れ下がったアクリレート基を有するイソシアヌレート誘導体、少なくとも1個の垂れ下がったアクリレート基を有するイソシアネート、およびこれらの混合物からなる群から選択される。
【0029】
アクリレート化ウレタンはヒドロキシ末端イソシアネート(NCO)伸張ポリエステルまたはポリエーテルのジアクリレートエステルである。市販されているアクリレートウレタンの代表例には、モートン・チオコール社から得られるユビタン782、およびラドキュア・スペシャルティーズ社より得られるCMD6600、CMD8400およびCMD8805が含まれる。アクリレート化エポキシは、ビスフェノールAエポキシ樹脂のジアクリレートエステルのようなジアクリレートエステルである。市販されているアクリレート化エポキシの例には、ラドキュア・スペシャルティーズ社より得られるCMD3500、CMD3600およびCMD3700が挙げられる。アミノプラスト誘導体は少なくとも1.1個の垂れ下がったα,β−不飽和カルボニル基を有し、これらはここに参照として挙げる米国特許第4,903,440号にさらに記載されている。
【0030】
エチレン性不飽和化合物には、炭素、水素および酸素、および必要に応じて、窒素およびハロゲンの原子を含むモノマーまたはポリマー化合物が含まれる。一般に、酸素および窒素原子はエーテル、エステル、ウレタン、アミドおよび尿素基中に存在する。このような材料の例は、すでにここに参照として挙げた米国特許第4,903,440号にさらに記載されている。少なくとも1個の垂れ下がったアクリレート基を有するイソシアネート誘導体およびイソシアヌレート誘導体は、ここに参照として挙げる米国特許第4,652,274号に記載されている。上述の接着剤はフリーラジカル重合機構により硬化する。
【0031】
本発明の研摩用品に好ましい他のバインダーには、ここで参照として挙げる米国特許第4,318,766号に記載の照射硬化性エポキシ樹脂が含まれる。この型の樹脂は、好ましくは、紫外線照射により硬化される。このエポキシ樹脂はヨードニウム光開始剤により開始されるカチオン重合機構により硬化される。
【0032】
エポキシ樹脂とアクリレート樹脂との混合物も用いうる。このような樹脂混合物の例は、ここに参照として挙げる米国特許第4,751,138号に記載されている。
【0033】
バインダーが紫外線照射により硬化される場合は、フリーラジカル重合を開始させるために光開始剤を必要とする。この目的に好ましい光開始剤の例には、有機パーオキシド、アゾ化合物、キノン、ベンゾフェノン、ニトロソ化合物、アクリルハライド、ヒドラゾン、メルカプト化合物、ピリリウム化合物、トリアクリルイミダゾール、ビスイミダゾール、クロロアルキルトリアジン、ベンゾインエーテル、ベンジルケタール、チオキサントンおよびアセトフェノン誘導体が含まれる。好ましい光開始剤は2,2−ジメトキシ−1,2−ジフェニル−1−エタノンである。
【0034】
バインダーが可視照射で硬化される場合は、光開始剤はフリーラジカル重合を開始させることが必要とされる。この目的のために好ましい光開始剤の例は、ここに参照として挙げる米国特許第4,735,632号、第3欄、第25行から第4欄第10行、第5欄第1〜7行、第6欄第1〜35行に記載されている。
【0035】
研摩グレインのバインダーに対する重量比は、一般に、1部のバインダーに対して約4〜1部の研摩グレイン、好ましくは1部のバインダーに対して約3〜2部の研摩グレインの範囲である。この割合は研摩グレインのサイズおよび用いるバインダーの型に依存して変化する。
【0036】
被覆研摩用品は、裏材料と研摩コンポジットとの間に設けられる任意の被覆を有しうる。この被覆は研摩コンポジットを裏材料に接合する機能を果たす。この被覆はコンポジットを調製するのに好ましいバインダー材料の群から調製されうる。
【0037】
研摩グレインおよびバインダーの他にも研摩コンポジットは他の材料を含みうる。この材料は添加剤と呼ばれ、カップリング剤、湿潤剤、染料、顔料、可塑剤、フィラー、剥離剤、研摩補助剤およびこれらの混合物が含まれる。コンポジットはカップリング剤を含むことが好ましい。カップリング剤を添加することにより、研摩コンポジットを形成するために用いるスラリーの被覆粘度を著しく低下させうる。本発明に好ましいこのようなカップリング剤の例には、有機シラン、ジルコアルミネートおよびチタネートが含まれる。カップリング剤の量は、一般に、バインダーの5重量%未満、好ましくは1重量%未満である。
【0038】
研摩コンポジットは少なくとも1種の予め定められた形状を有し、これらは予め定められた配列で配置される。一般に、予め定められた形状は一定の周期で繰り返される。この繰り返し形状は1方向的であるか、好ましくは2方向的である。表面プロファイルは繰り返し形状の再現性および持続性の指標である。表面プロファイルは以下の試験により決定されうる。
【0039】
表面プロファイル試験
試験される研摩用品を平坦表面上に置き、プロファイロメーター(東京精密社、日本、より市販のサーフコム・プロファイロメーター)由来のプローブ(半径5μm)で研摩コンポジットをトラバースした。このプローブは形状の配列に対して垂直に、かつ研摩用品の裏材料の平面に対して平行にトラバースした。当然であるが、プローブは研摩材の形状に接触する。プローブのトラバース速度は0.3mm/秒である。データ分析機は、東京精密社、日本、から得られるサーフライザー表面テクスチャ分析計で行った。このデータ分析機は、プローブが研摩用品のコンポジットをトラバースおよび接触するにつれて研摩コンポジットの形状のプロファイルをグラフ化する。本発明の場合は、グラフは繰り返し形状の一定の周期的な特徴を示す。用品の一領域のグラフを用品の他の領域のグラフと比較した場合に、出力の倍率および周波数は本質的に同一である。このことは、ランダムなパターンではなく、すなわち、非常に明確で正確な繰り返しパターンが存在することを意味する。
【0040】
研摩コンポジットの形状は一定の周期において繰り返えされる。典型的には、研摩コンポジットは高い頂点(すなわち、領域)と低い頂点(すなわち、領域)とを有する。データ分析機から得られる高い頂点値はそれぞれ10%内であり、データ分析機から得られる低い頂点値はそれぞれ10%内である。
【0041】
得られたプロファイルの例を図3に示す。パターンの周期性は「a’」で示す距離である。高い頂点値距離は「b’」のマークであり、低い頂点値距離は「c’」のマークである。
【0042】
表面プロファイル試験の代わりに以下の操作を用いうる。たとえば、図1に示すように、研摩用品の断面試料を撮る。ついで、この試料をホルダーに置き、試料を顕微鏡で観察する。試料を見るために走査電子顕微鏡および光学顕微鏡のいずれをも用いうる。ついで、ホルダー中の試料の表面を従来のいずれかの方法により磨き、試料を顕微鏡で見る場合に表面がきれいになるようにする。試料を顕微鏡で見、この試料のマイクロ写真を撮る。ついで、このマイクロ写真をデジタル化する。この工程中に、xおよびy座標に割り当てることにより、研摩コンポジットの予め定められた形状および予め定められた配列を地図化する。
【0043】
第1試料と同様にして研摩用品の第2試料を調製する。第2試料は第1試料と同一平面を有しなければならず、そのことにより、第2試料の配列および形状が第1試料のそれらと同一のタイプであることを確実とする。第2試料をデジタル化した場合に、2個の試料のxおよびy座標が10%を越えて異ならなければ、形状および配列が予め定められたと結論しうる。座標が15%を越えて異なる場合は、形状および配列はランダムであり、予め定められていないと結論される。
【0044】
図1、6、7および18に示すように、明確な頂点により特徴づけられる研摩コンポジットにおいて、デジタル化されたプロファイルは配列にわたって異なる。言い替えると、頂点は外観において谷と異なる。したがって、第2の試料が調製される場合に、第2試料の断面が第1試料の断面と正確に対応するように、すなわち、頂点は頂点に、谷は谷に対応するように注意する必要がある。しかしながら、頂点または形状のそれぞれの領域は、頂点または形状の他の領域と実質的に同一の幾何配置を有する。したがって、頂点または形状の一領域におけるあるデジタル化されたプロファイルについて、頂点または形状の他の領域における他のデジタル化したプロファイルが第1領域と本質的に同一であることを見出しうる。
【0045】
本発明の研摩用品がより持続性であるほど、ワークピースに研摩用品により付与される仕上げが持続性となる。得られたプロファイルを有する研摩用品は高レベルの持続性を有する。というのも、研摩コンポジットの頂点の高さは通常10%を越えて変化しないからである。
【0046】
本発明の被覆研摩用品は従来の被覆研摩用品と比べていくつかの利点を示す。ある場合には、研摩用品は、予め定められた配列により位置させた研摩コンポジットを有さない研摩用品よりも長い寿命を有する。コンポジットの間の空間は削りくずを研摩用品から逃がすための手段を提供し、そのことにより、ローディングおよび使用中に生じる熱を減少させる。さらに、本発明の被覆研摩用品は表面において均一な摩耗および均一なグラインド力を示しうる。研摩用品を用いるにしたがって、研摩グレインは抜け落ち、新しい研摩グレインが露出し、そのことにより、研摩製品は長寿命、高く維持された研摩速度および製品の寿命にわたる表面仕上げの持続を有する。
【0047】
予め定められた配列で配置される研摩コンポジットは広範囲の形状および間隔にわたって変化しうる。図4および5に、リニアな曲線溝を示す。図6および7に、ピラミッド形状を示す。図8および9に、リニアな溝を示す。図1に、同一寸法および形状の突出14、および3面体プリズムエレメントから作製される構造表面を示す。図3に、ステップ31およびランド32の連続を示す。
【0048】
それぞれのコンポジットは、1個以上の平坦表面で定められる境界を有する。たとえば、図1では、平坦境界は15の番号で示される。図3では、平坦境界は33の番号で示される。好ましくは、研摩グレインは平坦境界の上に突出しない。このような構成により、グラインドの削りくずに起因するローディングの量が研摩用品において低減されると考えられる。平坦境界を調節することにより、研摩コンポジットはより持続的に再生される。
【0049】
コンポジットの最適形状は特定の研摩用途に依存する。コンポジットの領域密度、すなわち、単位面積当たりのコンポジットの数、が変化すれば異なる特性が得られる。たとえば、より高い領域密度はグラインディング中においてより低いコンポジット当たりの単位圧を提供し、そのことにより、より細かい表面仕上げを提供する。連続頂点の配列は、可撓性製品が得られるように配置されうる。オフハンドグラインディング用途のような中位の単位圧のためには、約0.3〜約1の範囲のアスペクト比の研摩コンポジットが好ましい。本発明の利点は、隣接形状上の対応点間の最大距離が1mmを下回り、特に0.5mmを下回りうることである。
【0050】
本発明の被覆研摩用品は以下の操作により調製されうる。まず、研摩グレインおよびバインダーを含有するスラリーを製造用具に導入する。第2に、前側および裏側を有する裏材料を製造用具の外側表面に導入する。スラリーは裏材料の前側を濡らすことにより中間用品を形成する。第3に、バインダーが少なくとも部分的に硬化またはゲル化され、その後製造用具の外側表面から中間用品が除去される。第4に、製造用具から被覆研摩用品が除去される。好ましくは、4工程は連続的に行なわれる。
【0051】
本発明の方法の模式的な工程図を図2に示す。スラリー100は圧力または重力により充填口102から製造用具104上に流れ、その中のキャビティ(非表示)中に満たされる。スラリー100がキャビティを完全に満たさない場合は、得られる被覆研摩用品は研摩コンポジットの表面上および/または研摩コンポジットの内部にボイドまたは微小な不完全部分を有する。製造用具にスラリーを導入する他の方法にはダイ被覆および真空ドロップダイ被覆が含まれる。
【0052】
製造用具104に導入される前にスラリー100は加熱されることが好ましい。典型的には、40〜90℃の範囲の温度に加熱される。スラリー100が加熱される場合は、それは製造用具104のキャビティ中により容易に流れ、そのことにより、不完全部分が最低限となる。研摩スラリーの粘度はいくつかの理由で精密に制御することが好ましい。たとえば、粘度が高過ぎると研摩スラリーを製造用具に導入することが困難となる。
【0053】
製造用具104はベルト、シート、被覆ロール、被覆ロール上に装着されたスリーブまたはダイでありうる。製造用具104は被覆ロールであることが好ましい。典型的には、被覆ロールは24および45cmの間の直径を有し、金属のような剛性材料で構成される。製造用具104が一旦被覆装置上に装着されると、これは出力駆動モータにより駆動される。
【0054】
製造用具104は表面上に少なくとも1個の特定された形状の予め定められた配列を有する。これは本発明の用品の研摩コンポジットの予め定められた配列および特定形状の逆(inverse)である。この方法のための製造用具は金属、たとえば、ニッケルから調製されうるけれども、プラスチックの用具も用いうる。金属製の製造用具は、彫り込み、ホビング(hobbing)、所望の形状に機械加工された複数の金属部分を束として組み立てること、または他の機械的手段、または電気的形成により作製される。好ましい方法はダイヤモンド加工(diamondo turning)である。このような技術は、ポリマー科学および技術百科、第8巻、ジョン・ワイレイ&サンズ社、1968年、第651〜655頁、および米国特許第3,689,346号、第7欄、第30〜55行にさらに記載されており、これらすべてをここに参照として挙げる。
【0055】
ある場合には、オリジナルの用具からプラスチックの製造用具を複製しうる。金属用具と比較した場合のプラスチック用具の利点はコストである。ポリプロピレンのような熱可塑性樹脂は金属用具上でその溶融温度においてエンボス可能であり、金属用具の熱可塑性レプリカを提供する。このプラスチックのレプリカも製造用具として用いうる。
【0056】
照射硬化性バインダーのためには、製造用具は、典型的には30〜140℃の範囲に加熱され、そのことにより、より容易な処理および研摩用品の剥離を提供する。
【0057】
裏材料106は巻き戻しステーション108から出発し、ついで、アイドラーロール110およびニップロール112を通過することにより適当な張力を得る。ニップロール112は、裏材料106をスラリー100に押しつけ、そのことによりスラリーを裏材料106に濡らしつけ、中間用品を形成する。
【0058】
中間用品が製造用具104を離れる前にバインダーが硬化またはゲル化される。ここで用いられる「硬化」と言う用語は固体状態に重合させることを意味する。「ゲル化」はほぼ固体状に非常に粘性となることを意味する。硬化またはゲル化の後に研摩コンポジットの被覆研摩用品が製造用具104から分離した後は、研摩コンポジットの特定形状は変化しない。ある場合には、まずバインダーがゲル化され、ついで、中間用品が製造用具104から除去されうる。ついで、バインダーがその後硬化される。寸法的な特徴が変化しないために、得られる被覆研摩用品は非常に正確なパターンを有する。したがって、被覆研摩用品は製造用具104の逆のレプリカ(inverse replica)である。
【0059】
バインダーは、熱、赤外線照射または、電子線照射、紫外線照射または可視光照射のような他の照射エネルギーのようなエネルギーを提供するエネルギー源114により硬化またはゲル化される。用いるエネルギー源は、用いられる特定の接着剤および裏材料に依存する。縮合硬化性樹脂は熱、ラジオ周波数、マイクロ波または赤外線照射により硬化されうる。
【0060】
付加重合性樹脂は、熱、赤外線、または好ましくは電子線照射、紫外線照射または可視光照射により硬化されうる。好ましくは、電子線照射は0.1〜10Mrad、より好ましくは1〜6Mradの線量レベルを有する。紫外線照射は200〜700nm、より好ましくは250〜400nmの範囲の波長を有する非粒子照射である。可視照射は400〜800nm、より好ましくは400〜550nmの間の範囲の波長を有する非粒子照射である。紫外線照射が好ましい。一定のレベル照射における硬化速度はバインダーの厚さ、ならびに密度、温度および組成物の特性に依存して変化する。
【0061】
被覆研摩用品116は製造用具104から出発し、アイドラロール118を横切って巻き取りスタンド120に達する。研摩コンポジットは裏材料に良好に接着する必要がある。そうでなければ、コンポジットが製造用具104に残ることとなる。被覆研摩用品116の剥離を増大させるために、製造用具104は、シリコーン材料のような剥離剤で被覆されるか、それらを含有することが好ましい。
【0062】
用いられる特定のパターンおよび研摩用品に意図される用途に依存して、研摩用品は使用前に可撓化されることが好ましい場合もある。
【0063】
また、研摩用品は以下の方法によっても製造される。第1に、バインダーと複数の研摩グレインとの混合物を有するスラリーが前側および裏側を有する裏材料に導入される。このスラリーは裏材料の前側を濡らし、中間用品を形成する。第2に、中間用品が製造用具に導入される。第3に、中間用具が製造用具の外側面から分離する前にバインダーが少なくとも部分的に硬化またはゲル化され、研摩用品が形成される。第4に、研摩用品が製造用具から除去される。好ましくは、この工程は連続的に行なわれる。そのことにより、被覆研摩用品を調製するための効率的な方法が提供される。
【0064】
第2の方法は、第1の方法とほぼ同様であるが、最初にスラリーが製造用具にではなく裏材料に設けられる点で異なる。たとえば、スラリーは巻き戻しステーション108とアイドラロール110との間において裏材料に設けうる。第2の方法の他の工程および条件は第1の方法と同様である。製造用具の表面の特定の構成に依存して、第1の方法の代わりに第2の方法を用いことが好ましい。
【0065】
第2の方法では、スラリーは、ダイ被覆、ロール被覆または真空ダイ被覆のような方法により裏材料の前側に設けられうる。スラリーの重量は裏材料の張力およびニップ圧およびスラリーの流速により調製されうる。
【0066】
以下の非限定的な実施例により本発明をさらに説明する。実施例におけるすべての重量はg/m2で与えられる。以下の実施例のすべての割合は重量基準である。実施例で用いる溶融アルミナは白色溶融アルミナである。
【0067】
【実施例】
実施例において以下の略号を用いた。
【表1】
【0068】
乾燥押し引き試験
研摩用品を直径2.54cmのディスクとした。二重被覆転写テープを裏材料の裏側にラミネートした。ついで、被覆研摩用品を直径2.54cmのファインセ−イットの商標のバックアップパッド、ミネソタ・マイニング・アンド・マニファクチュアリング社、セント・ポール、ミネソタより市販されている、に押し付けた。ワークピースはウレタン下塗りを有する45cm×77cm金属板とした。このタイプのプライマーは自動車ペイント業界で通常用いられる。被覆研摩用品を用いて、手で、シート上を約三十(30)2.54cm×22cmの位置を研摩した。作業者の手は前後に移動しストロークを形成した。カット、すなわち、除去されたプライマーのマイクロメーターにおける量を100ストロークの後に測定した。エルコメーター・インスツルメント社、マンチェスタ、イングランド、より得られるエルコメーター測定機で塗料の厚さを測定した。仕上げ、すなわち、金属下塗り板の表面仕上げを10〜100ストロークの後に測定した。ローク・テイラー・ホブソン社、ライチェスター、イングランド、より得られるサートロニック3プロファイロメーター用いて仕上がり(Ra)を測定した。Raはマイクロインチにおけるスクラッチサイズの算術平均とした。
【0069】
湿潤押し引き試験
流水下で下塗り金属板表面で行うこと以外は乾燥押し引き試験と同様にして湿潤押し引き試験を行った。
【0070】
実施例1〜5
実施例1〜5の被覆研摩用品では、本発明の研摩用品の種々の形状および配列を説明する。これらの用品はバッチ法の手法により作製した。実施例1はLP1配列を、実施例2はLP2配列を、実施例3はLP3配列を、実施例4はLP4配列を、そして実施例5はCC配列を説明する。
【0071】
製造用具は配列の逆を有する16cm×16cmスクエアのニッケル板とした。製造用具は従来の電子形成法により作製した。裏材料は、フィルムを下塗りするためにCF4コロナで処理したポリエステルフィルム(厚さ0.5mm)とした。バインダーは、90%TMDIMA2/10%IBA/10%PH1接着剤からなる。研摩グレインは溶融アルミナ(平均粒子寸法40μm)とし、そしてスラリー中の研摩グレインとバインダーとの重量比を1:1とした。このスラリーを製造用具に塗布した。ついで、ポリエステルフィルムをスラリー上に設け、ゴムロールをポリエステルフィルム上に通過させることにより、フィルムの表面をスラリーで濡らした。ついで、スラリーを有する製造用具および裏材料を紫外線に露出することにより接着剤を硬化させた。それぞれの試料の用品を、400ワット/インチにおいて40フィート/分の速度で運転されるAETEK紫外線ランプに3回通過させた。ついで、それぞれの試料の用品を製造用具から除去した。実施例1〜5の研摩用品を乾燥押し引き試験および湿潤押し引き試験で試験した。乾燥押し引き試験の結果を表1に、湿潤押し引き試験の結果を表2に示す。図10に、実施例1の被覆研摩用品のための表面プロファイル試験のアウトプットを示す。
【0072】
【表2】
【0073】
【表3】
【0074】
実施例6
配列をLP5とすること以外は実施例1〜5の用品を調製するのに用いたのと同様にして、実施例6の被覆研摩用品を作製した。湿潤押し引き試験の結果を以下の表3に示す。
【0075】
比較例Aは、ミネソタ・マイニング・アンド・マニファクチュアリング社、セント・ポール、ミネソタより市販されているグレード600ウェットオアドライ・TRI−M−ITE紙被覆研摩材料とした。
【0076】
比較例Bは、ミネソタ・マイニング・アンド・マニファクチュアリング社、セント・ポール、ミネソタより市販されているグレード320ウェットオアドライ・TRI−M−ITE紙被覆研摩材料とした。
【0077】
【表4】
【0078】
以上の結果より、これらの形状はシャープな特徴(features)、すなわち、ポイントまたはリッジのいずれかを有することがもっとも効果的であり、フラットな特徴を有するこれらの形状はプライマーの除去において効果的でないことがわかる。さらに、CC配列は静的に可撓性(quiet flexible)であるがLP3配列は限られた可撓性を示した。
【0079】
実施例6の用品(LP5配列)はパターンにおいて指向性を有する。実施例6の用品を、改変乾燥押し引き試験で試験した。その際に、1ストロークを前進または後退の一方向における移動とした。結果を以下の表4に示す。
【0080】
【表5】
【0081】
実施例7〜 11
12μmの平均粒子寸法を有する溶融アルミナグレインを用いること以外は実施例1〜5の操作と同様にして、実施例7〜11の被覆研摩用品を作製した。実施例7ではLP2配列を説明し、実施例8ではLP1配列を説明し、実施例9ではCC配列を説明し、実施例10ではLP5配列を説明し、そして実施例11ではLP3配列を説明する。これらの実施例の研摩用品は湿潤押し引き試験で試験し、試験結果を以下の表5に示す。
【0082】
比較実施例Aは、ミネソタ・マイニング・アンド・マニファクチュアリング社、セント・ポール、ミネソタより市販されているグレード600ウェットオアドライ・TRI−M−ITEのウエイト紙とした。
【0083】
【表6】
【0084】
実施例 12 〜 14
90μmの平均粒子サイズを有する溶融アルミナグレインを用いること以外は実施例1〜5に記載の方法と同様にして、実施例12〜14の研摩用品を作製した。実施例12ではLP3配列を、実施例13ではLP5配列を、実施例14ではCC配列を説明する。これらの実施例の研摩用品を乾燥押し引き試験で試験した。結果を表6に示す。
【0085】
比較例Bは、ミネソタ・マイニング・アンド・マニファクチュアリング社、セント・ポール、ミネソタより市販されているグレード320・ウェットオアドライ・TRI−M−ITEのAウエイト紙とした。
【0086】
【表7】
【0087】
表7では、乾燥押し引き試験において、40μmの平均粒子寸法を有する研摩用品(実施例3)と12μmの平均粒子寸法を有する研摩用品(実施例11)との性能の比較を示す。
【0088】
【表8】
【0089】
LP3配列において、カットは研摩グレインの特定のサイズよりもコンポジットの配列および形状により依存する。従来は、用いる研摩グレインのサイズはカットに著しく影響すると考えられてきた。この現象は驚くべきことであり、当業界で一般に考えられてきたのとは逆である。
【0090】
実施例 15 〜 16 、および比較例 C および D
これらの実施例では、従来の被覆研摩用品と本発明の被覆研摩用品との性能を比較する。これらの実施例の被覆研摩用品は連続法により作製され、カットを除去されたプライマーのグラムにおける量とすること以外は乾燥押し引き試験と同様にして試験した。さらに、試験の終わりに表面仕上げをとり、RaおよびRTMの両方をマイクロインチにおいて測定した。RTMは最も深いスクラッチの秤量された平均測定とした。結果を表8に示す。
【0091】
図2に示したのと実質的同様の装置でこれらの実施例のための被覆研摩用品を調製した。研摩グレインを含有するスラリー100を製造用具104に充填口102から導入した。ついで、スラリー100が裏材料の表面を濡らし、中間用品を形成するように、裏材料を製造用具104に導入した。裏材料は圧力ロール112を用いてスラリー100に押し付けた。スラリー100中のバインダーを硬化させることにより被覆研摩用品を形成した。ついで、製造用具104から被覆研摩用品を除去した。スラリーおよび裏材料は実施例1で用いたのと同一の材料を用いた。バインダーの温度を30℃、そして製造用具の温度を70℃とした。
【0092】
実施例 15 〜 16
実施例15および16において、製造用具上でスラリーを硬化させるように紫外線ランプを位置させた。実施例15では、製造用具はLP6配列を有するグラビアロールとした。実施例16では、製造用具はCC配列を有するグラビアロールとした。
【0093】
比較例 C および D
比較例CおよびDにおいては、製造用具から除去された後にスラリーが硬化されるように紫外線ランプを位置させた。したがって、中間用品が製造用具に残される時と、接着剤が硬化またはゲル化される時との間に時間のズレが生じる。この遅れにより接着剤が流動し、コンポジットの配列および形状が変化する。比較例Cにおいて、製造用具はCC配列を有し、比較例Dにおいて製造用具はLP6配列を有していた。
【0094】
従来の被覆研摩用品と比較した場合に、本発明の被覆研摩用品における改良点は製造用具における硬化またはゲル化から得られる。この改良点は図6、7、15および16の写真より容易に認められる。図15および16は比較例Cのものであるが、図6および7は実施例16のものである。図11に、比較例Dの被覆研摩用品の表面プロファイル試験のアウトプットを示す。
【0095】
【表9】
【0096】
最も好ましい被覆研摩製品は低い表面仕上がり値とともに高いカットを有するものである。本発明の研摩用品はこの基準を満足する。
【0097】
実施例 17 〜 20
これらの実施例の研摩用品は種々の接着剤の硬化を説明する。異なる接着剤を用いること以外は実施例1と同様の方法により研摩用品を作製し試験した。スラリー中の材料の重量比は実施例1と同一とした。実施例17のための接着剤をTMDIMA2とし、実施例18のための接着剤をBAMとし、実施例19のための接着剤をAMPとし、そして実施例20のための接着剤をTATHEICとした。試験結果を以下の表9に示す。比較例Aは、ミネソタ・マイニング・アンド・マニファクチュアリング社、セント・ポール、ミネソタより市販されているグレード600ウェットオアドライ・TRI−M−ITEのAウエイト紙とした。
【0098】
【表10】
【0099】
実施例 21 〜 24
異なるスラリーを用いること以外は実施例16と同様の方法で実施例21〜24の被覆研摩用品を作製した。実施例21においては40μmの平均粒子サイズの溶融アルミナグレイン(100部)/TMDIMA2(90部)/IBA(10部)/PH1(2部)からなる研摩スラリーを用い、実施例22では40μmの平均粒子サイズの溶融アルミナグレイン(200部)/TMDIMA2(90部)/IBA(10部)/PH1(2部)からなる研摩スラリーを用い、実施例23では40μmの平均粒子寸法の溶融アルミナグレイン(200部)/AMP(90部)/IBA(10部)/PH1(2部)からなる研摩スラリーを用い、そして実施例24では、40μmの平均粒子寸法の溶融アルミナグレイン(200部)/TATHEIC(90部)/IBA(10部)/PH1(2部)からなる研摩スラリーを用いた。比較例Eは、ミネソタ・マイニング・アンド・マニファクチュアリング社、セント・ポール、ミネソタより市販されているグレード400ウェットオアドライ・TRI−M−ITEのAウエイト紙とした。
【0100】
ラップ試験
研摩用品を直径35.6cmのディスクとし、RHストラスバーグ6AXラッピング装置で試験した。ワークピースは直径7.5cmの円形に揃え、ホルダーにセットした直径1.2cmの3個の1018スチールロッドとした。ラッピングは水を用いないで行い、ワークピースへの通常の(鉛直の)負荷は1kgとした。ワークピース駆動スピンドルを7.6cmにオフセットした。ラップの中心からワークピース駆動スピンドル回転を63.5rpmとした。ラップは65rpmで回転させた。被覆研摩ディスクは二重被覆テープで研摩ホルダーに装着した。累積カット量を測定するために、5、15、30および60分間隔で試験を中断した。試験結果を以下の表10に示す。
【0101】
【表11】
【0102】
コンポジットの適当な配列および形状の選択により、カット速度が最大化され得、スクラッチ深さが最小化され得、そしてスクラッチパターンの均一性が最大化されうる。
【0103】
本発明の被覆研摩用品は比較例Eの被覆研摩用品のように負荷が大きくない。本発明の被覆研摩用品のコンポジットの均一な配列および形状はその性能の増大に寄与する。
【0104】
本発明の被覆研摩用品を調製するための製造用具の製造の領域におけるガイダンスを提供するために、被覆研摩用品のための以下の寸法を提供するものを包括的に図12〜14、および包括的に17〜19に示す。寸法、すなわち、インチまたはアーク(arc)の度、は以下の表11に示す。
【0105】
【表12】
【0106】
本発明の視野および精神から離れることなく本発明の種々の変形および改変が当業者にとって明白であり、そして本発明はここに例示の限定的な説明のための実施態様に限ると解されるべきではない。
【図面の簡単な説明】
【図1】本発明の研摩用品の断面の横面図である。
【図2】本発明の研摩用品を作製するための装置の模式図である。
【図3】本発明の研摩用品の外観図である。
【図4】リニアな溝の配列を有する研摩用品の上面の30倍の倍率で撮った走査電子顕微鏡写真である。
【図5】リニアな溝の配列を有する被覆研摩用品の横面の100倍の倍率で撮った走査電子顕微鏡写真である。
【図6】ピラミッド形状の配列を有する研摩用品の上面を20倍の倍率で撮った走査電子顕微鏡写真である。
【図7】ピラミッド形状の配列を有する研摩用品の側面を100倍の倍率で撮った走査電子顕微鏡写真である。
【図8】鋸刃形状の配列を有する研摩用品を30倍の倍率で撮った走査電子顕微鏡写真(上面)である。
【図9】鋸刃形状の配列を有する研摩用品を30倍の倍率で撮った走査電子顕微鏡写真(側面)である。
【図10】本発明の研摩用品の表面プロファイル試験由来のグラフである。
【図11】従来技術により作製した研摩用品の表面プロファイル試験由来のグラフである。
【図12】リニアな溝の配列のための前面模式図である。
【図13】リニアな溝の配列のための前面模式図である。
【図14】リニアな溝の配列のための前面模式図である。
【図15】従来技術の研摩用品を20倍の倍率で撮った走査電子顕微鏡写真の上面図である。
【図16】従来技術の研摩用品を100倍の倍率で撮った電子顕微鏡写真の上面図である。
【図17】特定パターンの配列のための前面模式図である。
【図18】特定パターンの配列のための前面模式図である。
【図19】特定パターンの配列のための前面模式図である。[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to an abrasive article having a backing having an adhered composite abrasive.
[0002]
[Prior art]
Two major problems with abrasive articles, especially fine grade articles, are loading and product sustainability. Loading is a problem caused by the space between the abrasive grains being filled with shavings (ie, material removed from the workpiece being polished), which builds up. For example, when sanding wood, the sawdust particles lodge between the abrasive grains, thereby reducing the cutting ability of the abrasive grains and creating the possibility of burning the surface of the wood workpiece.
[0003]
U.S. Pat. No. 2,252,683 (Albertson) discloses an abrasive having a backing material and a plurality of abrasive grains joined to the backing material by a resinous adhesive. During manufacture, before the resinous adhesive is cured, the abrasive article is placed in a heated mold having a pattern. The reverse pattern is transferred to the backing material.
[0004]
U.S. Pat. No. 2,292,261 (Albertson) discloses an abrasive article having a fibrous backing having an abrasive coating thereon. The abrasive coating has abrasive particles embedded in a binder. If the binder is not cured, the abrasive coating is processed with a pressure die having a plurality of ridges. This results in an abrasive coating having rectangular grooves embossed vertically and horizontally.
[0005]
U.S. Pat. No. 3,246,430 (Hearst) discloses an abrasive article having a fibrous backing material impregnated with a thermoplastic adhesive. After the backing has been processed in a continuous ridge pattern, a bonding system and abrasive grains are provided. This results in an abrasive article having high and low ridges of abrasive grains.
[0006]
U.S. Pat. No. 4,539,017 (Augustin) discloses an abrasive article having a backing, a support layer of an elastomeric material on the backing, and an abrasive coating adhered to the support layer. The abrasive coating consists of abrasive grains dispersed throughout a binder. Further, the abrasive coating can be in the form of a pattern.
[0007]
U.S. Pat. No. 4,773,920 (Chassman et al.) Describes an abrasive lapping article having an abrasive composite formed from abrasive grains dispersed over a free radical curable binder. The patent also discloses that the abrasive composite can be formed into a pattern by rotogravure rolls.
[0008]
Although some of the abrasive articles made according to the above-mentioned patents are loading resistant and inexpensive to manufacture, they lack a high level of durability. If the abrasive article is made in a conventional manner, the adhesive or binder system may flow before or during cure, thereby adversely affecting product durability.
[0009]
A need exists for a loading resistant and inexpensive abrasive article that has a high level of durability.
[0010]
[Patent Document 1]
U.S. Pat. No. 2,252,683
[Patent Document 2]
U.S. Pat. No. 2,292,261
[Patent Document 3]
U.S. Pat. No. 3,246,430
[Patent Document 4]
US Patent No. 4539017
[Patent Document 5]
U.S. Pat. No. 4,773,920
[0011]
[Summary of the Invention]
The present invention provides structured abrasive articles and methods for preparing such articles.
[0012]
In one aspect, the invention includes a coated abrasive article having a backing material on at least one major surface that supports an abrasive composite having a plurality of abrasive grains dispersed in a binder. The binder functions as a medium for dispersing the abrasive grains, which bonds the abrasive composite to the backing. The abrasive composite has a predetermined shape, for example, a pyramid. Prior to use, it is preferred that the individual abrasive grains do not protrude beyond the plane of the predetermined shape. The dimensions of a given shape can be substantially uniform. Further, the composites are arranged in a predetermined arrangement. This predetermined sequence may indicate a certain repetition. The repeating pattern of the predetermined arrangement may be linear or matrix-shaped.
[0013]
In another aspect, the invention includes a coated abrasive article having a backing material that supports on at least one major surface an abrasive composite having a plurality of abrasive grains dispersed in a radiation curable binder. The abrasive composite has a predetermined shape arranged in a predetermined arrangement.
[0014]
The correct properties of the abrasive composite provide an abrasive article having a high level of durability. In addition, this persistence provides excellent performance.
[0015]
In still another aspect, the present invention includes the following steps. A method for making a coated abrasive article is provided.
(1) introducing a slurry containing a mixture of a binder and a plurality of abrasive grains onto a production tool;
(2) forming an intermediate article by introducing the backing material to the outer surface of the manufacturing tool such that the slurry wets one major surface of the backing material;
(3) forming a coated abrasive article by at least partially curing or gelling the binder before the intermediate article separates from the outer surface of the production tool; and
(4) removing the coated abrasive article from the production tool;
[0016]
Preferably, the four steps are performed sequentially, which provides an efficient method of making a coated abrasive article. In any of the manufacturing embodiments, after the slurry is introduced into the manufacturing tool, the slurry does not exhibit any appreciable flow prior to hardening or gelling.
[0017]
In yet another aspect, the present invention provides a method of making a coated abrasive article comprising the following steps.
(1) forming an intermediate article by introducing a slurry comprising a mixture of a binder and a plurality of abrasive grains onto the backing material such that the slurry wets the front side of the backing material;
(2) introducing the intermediate article into a production tool having an outer surface;
(3) forming a coated abrasive article by at least partially curing or gelling the binder before the intermediate article separates from the outer surface of the production tool; and
(4) removing the coated abrasive article from the production tool;
[0018]
Preferably, the four steps are performed sequentially, which provides an efficient method for making a coated abrasive article. In any of the manufacturing embodiments, after the slurry is introduced into the manufacturing tool, the slurry does not exhibit any appreciable flow prior to hardening or gelling.
[0019]
[Detailed description]
The present invention provides structured abrasive articles and methods for making such articles. As used herein, the term "structured abrasive article" refers to an abrasive article in which composites having abrasive grains dispersed in a binder have a predetermined shape and are arranged in a predetermined array. Means
[0020]
In FIG. 1, a coated abrasive article 10 has a
[0021]
Preferred materials for the backing material of the present invention include polymer films, papers, fabrics, metal films, vulcan fibers, non-woven substrates, combinations thereof, and treated products thereof. The backing material is preferably a polymer film such as a polyester film. In some cases, it is desirable that the backing be transparent to ultraviolet radiation. Also, the film is preferably primed with a material such as polyethylene acrylic acid to promote adhesion of the abrasive composite to the backing material.
[0022]
After forming the coated abrasive article, the backing material can be laminated to another substrate. For example, the backing material is laminated to a stiffer, more rigid substrate, such as a metal plate, to provide a coated abrasive article having a precise abrasive composite supported on a rigid support.
[0023]
The surface of the backing material without the abrasive composite may have a pressure sensitive adhesive or hook and loop type attachment device so that the abrasive article can be secured to a backup pad. Examples of pressure-sensitive adhesives suitable for this purpose include rubber-based adhesives, acrylate-based adhesives and silicone-based adhesives.
[0024]
The abrasive composite is formed from a slurry containing a plurality of abrasive grains dispersed in an uncured or ungelled binder. Upon curing or gelling, the abrasive composite is solidified, that is, fixed in a predetermined shape and predetermined arrangement.
[0025]
The size of the abrasive grains can range from about 0.5 to about 1000 μm, preferably from about 1 to about 100 μm. Often, a narrow particle size dispersion provides an abrasive article that can provide a finer finish to the workpiece being polished. Examples of abrasive grains suitable for the present invention include molten aluminum oxide, heat treated aluminum oxide, ceramic aluminum oxide, silicon carbide, alumina zirconia, garnet, diamond, cubic boron nitride, and mixtures thereof.
[0026]
The binder must provide a medium in which the abrasive grains can be dispersed. Preferably, the binder cures or gels relatively quickly, allowing the abrasive article to be manufactured quickly. Some binders gel relatively quickly, but take longer to fully cure. Gelation maintains the shape of the composite until curing begins. Fast curing or fast gelling binders result in coated abrasive articles having a high durability abrasive composite. Examples of preferred binders for the present invention include phenolic resins, aminoplast resins, urethane resins, epoxy resins, acrylate resins, acrylated isocyanurate resins, urea-formaldehyde resins, isocyanurate resins, acrylated urethane resins, acrylated epoxy resins , Glue and mixtures thereof. The binder may be a thermoplastic resin.
[0027]
Depending on the binder used, curing or gelling can be effected by an energy source such as heat, infrared, electron beam, ultraviolet radiation or visible light radiation.
[0028]
As mentioned above, the binder may be radiation curable. Irradiation curable binders are any binders that can be at least partially cured or at least partially polymerized by irradiation energy. Typically, these binders are polymerized by a free radical mechanism. Preferably, these are acrylated urethanes, acrylated epoxies, aminoplast derivatives having a pendant α, β-unsaturated carbonyl group, ethylenically unsaturated compounds, isocyanurate derivatives having at least one pendant acrylate group, It is selected from the group consisting of isocyanates having at least one pendant acrylate group, and mixtures thereof.
[0029]
Acrylated urethanes are diacrylate esters of hydroxy terminated isocyanate (NCO) extended polyesters or polyethers. Representative examples of commercially available acrylate urethanes include Ubitan 782 from Morton Thiokol, and CMD6600, CMD8400, and CMD8805 from Radcure Specialties. Acrylated epoxies are diacrylate esters, such as the diacrylate esters of bisphenol A epoxy resins. Examples of commercially available acrylated epoxies include CMD3500, CMD3600 and CMD3700 obtained from Radcure Specialties. The aminoplast derivatives have at least 1.1 pendent α, β-unsaturated carbonyl groups, which are further described in U.S. Pat. No. 4,903,440, which is incorporated herein by reference.
[0030]
Ethylenically unsaturated compounds include monomeric or polymeric compounds containing carbon, hydrogen and oxygen, and optionally nitrogen and halogen atoms. Generally, oxygen and nitrogen atoms are present in ether, ester, urethane, amide and urea groups. Examples of such materials are further described in U.S. Pat. No. 4,903,440, which was previously incorporated herein by reference. Isocyanate and isocyanurate derivatives having at least one pendent acrylate group are described in US Pat. No. 4,652,274, incorporated herein by reference. The adhesive described above cures by a free radical polymerization mechanism.
[0031]
Other preferred binders for the abrasive article of the present invention include the radiation curable epoxy resins described in U.S. Pat. No. 4,318,766, which is incorporated herein by reference. This type of resin is preferably cured by UV irradiation. The epoxy resin is cured by a cationic polymerization mechanism initiated by an iodonium photoinitiator.
[0032]
Mixtures of epoxy and acrylate resins may also be used. Examples of such resin mixtures are described in U.S. Pat. No. 4,751,138, incorporated herein by reference.
[0033]
If the binder is cured by UV irradiation, a photoinitiator is required to initiate free radical polymerization. Examples of preferred photoinitiators for this purpose include organic peroxides, azo compounds, quinones, benzophenones, nitroso compounds, acryl halides, hydrazones, mercapto compounds, pyrylium compounds, triacrylimidazoles, bisimidazoles, chloroalkyl triazines, benzoin ethers, Includes benzyl ketal, thioxanthone and acetophenone derivatives. A preferred photoinitiator is 2,2-dimethoxy-1,2-diphenyl-1-ethanone.
[0034]
If the binder is cured with visible radiation, the photoinitiator is required to initiate free radical polymerization. Examples of preferred photoinitiators for this purpose are described in U.S. Pat. No. 4,735,632,
[0035]
The weight ratio of abrasive grains to binder generally ranges from about 4-1 parts abrasive grains to 1 part binder, preferably from about 3 to 2 parts abrasive grains to 1 part binder. This ratio will vary depending on the size of the abrasive grains and the type of binder used.
[0036]
The coated abrasive article can have any coating provided between the backing and the abrasive composite. This coating serves to bond the abrasive composite to the backing material. The coating can be prepared from the group of binder materials that are preferred for preparing composites.
[0037]
In addition to the abrasive grains and binder, the abrasive composite may include other materials. This material is called an additive and includes coupling agents, wetting agents, dyes, pigments, plasticizers, fillers, release agents, abrasive aids and mixtures thereof. Preferably, the composite contains a coupling agent. The addition of the coupling agent can significantly reduce the coating viscosity of the slurry used to form the abrasive composite. Examples of such coupling agents preferred for the present invention include organosilanes, zircoaluminates and titanates. The amount of coupling agent is generally less than 5% by weight of the binder, preferably less than 1% by weight.
[0038]
The abrasive composite has at least one predetermined shape, which are arranged in a predetermined arrangement. Generally, a predetermined shape is repeated at a constant cycle. This repetitive shape is unidirectional or, preferably, bidirectional. The surface profile is a measure of the reproducibility and persistence of the repeating shape. The surface profile can be determined by the following test.
[0039]
Surface profile test
The abrasive article to be tested was placed on a flat surface, and the abrasive composite was traversed with a probe (5 μm radius) from a profilometer (Surfcom Profiler, commercially available from Tokyo Seimitsu, Japan). The probe traversed perpendicular to the geometry array and parallel to the plane of the abrasive article backing. Of course, the probe contacts the shape of the abrasive. The traverse speed of the probe is 0.3 mm / sec. The data analyzer was performed with a surface riser surface texture analyzer obtained from Tokyo Seimitsu, Japan. The data analyzer graphs the profile of the abrasive composite shape as the probe traverses and contacts the abrasive article composite. In the case of the present invention, the graph shows certain periodic features of the repetitive shape. When comparing a graph of one area of the article to a graph of another area of the article, the magnification and frequency of the output are essentially the same. This means that there is no random pattern, ie, there is a very clear and accurate repeating pattern.
[0040]
The shape of the abrasive composite is repeated at regular intervals. Typically, the abrasive composite has a high vertex (ie, region) and a low vertex (ie, region). The high vertex values obtained from the data analyzer are each within 10%, and the low vertex values obtained from the data analyzer are each within 10%.
[0041]
FIG. 3 shows an example of the obtained profile. The periodicity of the pattern is a distance indicated by “a ′”. The high vertex value distance is a mark of “b ′”, and the low vertex value distance is a mark of “c ′”.
[0042]
The following procedure can be used instead of the surface profile test. For example, as shown in FIG. 1, a cross-sectional sample of an abrasive article is taken. Then, the sample is placed on a holder, and the sample is observed with a microscope. Either a scanning electron microscope or an optical microscope can be used to view the sample. The surface of the sample in the holder is then polished by any conventional method so that the surface is clean when the sample is viewed under a microscope. View the sample under a microscope and take a microphotograph of the sample. The microphoto is then digitized. During this step, a predetermined shape and predetermined arrangement of the abrasive composite are mapped by assigning them to x and y coordinates.
[0043]
A second sample of the abrasive article is prepared in the same manner as the first sample. The second sample must have the same plane as the first sample, thereby ensuring that the arrangement and shape of the second sample are of the same type as those of the first sample. When digitizing the second sample, if the x and y coordinates of the two samples do not differ by more than 10%, it can be concluded that the shape and arrangement were predetermined. If the coordinates differ by more than 15%, it is concluded that the shape and arrangement are random and not predetermined.
[0044]
As shown in FIGS. 1, 6, 7 and 18, in an abrasive composite characterized by distinct vertices, the digitized profile differs across the array. In other words, vertices differ from valleys in appearance. Therefore, when the second sample is prepared, care must be taken that the cross section of the second sample exactly corresponds to the cross section of the first sample, ie, the vertices correspond to the vertices and the valleys correspond to the valleys. There is. However, each region of the vertex or shape has substantially the same geometry as the other regions of the vertex or shape. Thus, for one digitized profile in one region of the vertex or shape, one may find that the other digitized profile in another region of the vertex or shape is essentially identical to the first region.
[0045]
The more persistent the abrasive article of the present invention, the more persistent the finish imparted to the workpiece by the abrasive article. Abrasive articles having the resulting profile have a high level of durability. This is because the height of the top of the abrasive composite usually does not change by more than 10%.
[0046]
The coated abrasive articles of the present invention exhibit several advantages over conventional coated abrasive articles. In some cases, the abrasive article has a longer life than an abrasive article that does not have the abrasive composite positioned in a predetermined arrangement. The space between the composites provides a means for escaping shavings from the abrasive article, thereby reducing the heat generated during loading and use. Further, the coated abrasive articles of the present invention can exhibit uniform wear and uniform grinding forces on the surface. As the abrasive article is used, the abrasive grains fall off, exposing new abrasive grains, so that the abrasive product has a long life, a high maintained polishing rate, and a sustained surface finish over the life of the product.
[0047]
The abrasive composites arranged in the predetermined arrangement can vary over a wide range of shapes and spacings. 4 and 5 show linear curved grooves. 6 and 7 show a pyramid shape. 8 and 9 show linear grooves. FIG. 1 shows a structural surface made from
[0048]
Each composite has a boundary defined by one or more flat surfaces. For example, in FIG. 1, flat boundaries are indicated by the
[0049]
The optimal shape of the composite depends on the particular polishing application. Different properties can be obtained if the area density of the composite, that is, the number of composites per unit area, changes. For example, a higher area density provides a lower unit pressure per composite during grinding, thereby providing a finer surface finish. An array of continuous vertices can be arranged to provide a flexible product. For moderate unit pressures, such as off-hand grinding applications, abrasive composites with aspect ratios ranging from about 0.3 to about 1 are preferred. An advantage of the present invention is that the maximum distance between corresponding points on adjacent shapes can be less than 1 mm, especially less than 0.5 mm.
[0050]
The coated abrasive article of the present invention can be prepared by the following operation. First, a slurry containing abrasive grains and a binder is introduced into a production tool. Second, a backing material having a front side and a back side is introduced to the outer surface of the production tool. The slurry forms an intermediate article by wetting the front side of the backing material. Third, the binder is at least partially cured or gelled, after which the intermediate article is removed from the outer surface of the manufacturing tool. Fourth, the coated abrasive article is removed from the production tool. Preferably, the four steps are performed sequentially.
[0051]
FIG. 2 shows a schematic process diagram of the method of the present invention.
[0052]
Preferably, the
[0053]
[0054]
[0055]
In some cases, plastic manufacturing tools can be duplicated from original tools. An advantage of plastic tools when compared to metal tools is cost. Thermoplastics such as polypropylene can be embossed on a metal tool at its melting temperature, providing a thermoplastic replica of the metal tool. Replicas of this plastic can also be used as manufacturing tools.
[0056]
For radiation curable binders, the manufacturing tool is typically heated to a range of 30-140 ° C., thereby providing easier processing and stripping of the abrasive article.
[0057]
The backing 106 starts at the
[0058]
The binder is cured or gelled before the intermediate article leaves the
[0059]
The binder is cured or gelled by an
[0060]
The addition polymerizable resin can be cured by heat, infrared radiation or, preferably, electron beam radiation, ultraviolet radiation or visible light radiation. Preferably, the electron beam irradiation has a dose level of 0.1 to 10 Mrad, more preferably 1 to 6 Mrad. Ultraviolet radiation is non-particle radiation having a wavelength in the range of 200-700 nm, more preferably 250-400 nm. Visible radiation is non-particle radiation having a wavelength in the range between 400 and 800 nm, more preferably between 400 and 550 nm. UV irradiation is preferred. The cure rate at a constant level of irradiation will vary depending on the thickness of the binder and the density, temperature and composition properties.
[0061]
Coated
[0062]
Depending on the particular pattern used and the application intended for the abrasive article, it may be preferable for the abrasive article to be flexible before use.
[0063]
Abrasive articles are also manufactured by the following method. First, a slurry having a mixture of a binder and a plurality of abrasive grains is introduced into a backing having a front side and a back side. This slurry wets the front side of the backing and forms an intermediate article. Second, an intermediate article is introduced into the production tool. Third, the binder is at least partially cured or gelled before the intermediate tool separates from the outer surface of the manufacturing tool to form an abrasive article. Fourth, the abrasive article is removed from the production tool. Preferably, this step is performed continuously. This provides an efficient method for preparing a coated abrasive article.
[0064]
The second method is substantially similar to the first method, except that the slurry is first applied to the backing material rather than to the production tool. For example, a slurry may be provided on the backing between the
[0065]
In a second method, the slurry can be applied to the front side of the backing by methods such as die coating, roll coating or vacuum die coating. The weight of the slurry can be adjusted by the backing tension and nip pressure and the flow rate of the slurry.
[0066]
The present invention is further described by the following non-limiting examples. All weights in the examples are g / m2Given by All percentages in the following examples are by weight. The fused alumina used in the examples is white fused alumina.
[0067]
【Example】
The following abbreviations were used in the examples.
[Table 1]
[0068]
Dry push-pull test
The abrasive article was a disk with a diameter of 2.54 cm. A double coated transfer tape was laminated to the back side of the backing. The coated abrasive article was then pressed into a 2.54 cm diameter Fine Sayte trademark backup pad, commercially available from Minnesota Mining and Manufacturing Company, St. Paul, Minn. The workpiece was a 45 cm × 77 cm metal plate with urethane undercoat. This type of primer is commonly used in the automotive paint industry. Using a coated abrasive article, the position of about thirty (30) 2.54 cm × 22 cm on the sheet was polished by hand. The operator's hand moved back and forth to form a stroke. The cut, ie, the amount of primer removed in the micrometer, was measured after 100 strokes. The paint thickness was measured with an Elcometer measuring instrument available from Elcometer Instruments, Manchester, England. Finish, i.e., the surface finish of the metal primed plate was measured after 10-100 strokes. Finish (Ra) was measured using a
[0069]
Wet push-pull test
The wet push-pull test was performed in the same manner as the dry push-pull test except that the test was performed on the surface of the undercoated metal plate under running water.
[0070]
Examples 1 to 5
The coated abrasive articles of Examples 1-5 illustrate various shapes and arrangements of the abrasive articles of the present invention. These articles were produced by a batch method. Example 1 describes the LP1 sequence, Example 2 describes the LP2 sequence, Example 3 describes the LP3 sequence, Example 4 describes the LP4 sequence, and Example 5 describes the CC sequence.
[0071]
The production tool was a 16 cm × 16 cm square nickel plate with the reverse of the arrangement. The manufacturing tool was manufactured by a conventional electron forming method. The backing material is CF to prime the film4A polyester film (thickness 0.5 mm) treated with corona was used. The binder consists of 90
[0072]
[Table 2]
[0073]
[Table 3]
[0074]
Example 6
A coated abrasive article of Example 6 was made in the same manner as used to prepare the articles of Examples 1-5, except that the sequence was LP5. Table 3 below shows the results of the wet push-pull test.
[0075]
Comparative Example A was a Grade 600 wet or dry TRI-M-ITE paper coated abrasive material commercially available from Minnesota Mining and Manufacturing Company, St. Paul, Minn.
[0076]
Comparative Example B was a grade 320 wet or dry TRI-M-ITE paper coated abrasive material commercially available from Minnesota Mining and Manufacturing Company, St. Paul, Minnesota.
[0077]
[Table 4]
[0078]
From the above results, it is most effective for these shapes to have sharp features, ie, either points or ridges, and those shapes having flat features are not effective in removing primer. You can see that. Furthermore, the CC array was statically flexible (quiet @ flexible) while the LP3 array showed limited flexibility.
[0079]
The article of Example 6 (LP5 array) has directivity in the pattern. The article of Example 6 was tested in a modified dry push-pull test. At this time, one stroke was defined as movement in one direction of forward or backward movement. The results are shown in Table 4 below.
[0080]
[Table 5]
[0081]
Example 7- 11
Coated abrasive articles of Examples 7 to 11 were produced in the same manner as in Examples 1 to 5, except that fused alumina grains having an average particle size of 12 µm were used. Example 7 describes the LP2 sequence, Example 8 describes the LP1 sequence, Example 9 describes the CC sequence, Example 10 describes the LP5 sequence, and Example 11 describes the LP3 sequence. . The abrasive articles of these examples were tested in a wet push-pull test, and the test results are shown in Table 5 below.
[0082]
Comparative Example A was a grade 600 wet or dry TRI-M-ITE weight paper commercially available from Minnesota Mining and Manufacturing Company, St. Paul, Minnesota.
[0083]
[Table 6]
[0084]
Example 12 ~ 14
Polishing articles of Examples 12 to 14 were produced in the same manner as in Examples 1 to 5, except that fused alumina grains having an average particle size of 90 µm were used. Example 12 describes the LP3 sequence, Example 13 describes the LP5 sequence, and Example 14 describes the CC sequence. The abrasive articles of these examples were tested in a dry push-pull test. Table 6 shows the results.
[0085]
Comparative Example B was Grade 320 wet or dry TRI-M-ITE A weight paper commercially available from Minnesota Mining and Manufacturing Company, St. Paul, Minnesota.
[0086]
[Table 7]
[0087]
Table 7 shows a comparison of the performance of an abrasive article having an average particle size of 40 μm (Example 3) and an abrasive article having an average particle size of 12 μm (Example 11) in a dry push-pull test.
[0088]
[Table 8]
[0089]
In the LP3 sequence, the cut is more dependent on the sequence and shape of the composite than on the particular size of the abrasive grains. Conventionally, it has been thought that the size of the abrasive grains used has a significant effect on the cut. This phenomenon is surprising, contrary to what has generally been considered in the art.
[0090]
Example Fifteen ~ 16 , And comparative examples C and D
These examples compare the performance of a conventional coated abrasive article with the coated abrasive article of the present invention. The coated abrasive articles of these examples were made by a continuous process and were tested in a manner similar to the dry push-pull test except that the cuts were in grams in the primer removed. In addition, a surface finish was taken at the end of the test, and both Ra and RTM were measured in microinches. RTM was the weighed average measurement of the deepest scratch. Table 8 shows the results.
[0091]
Coated abrasive articles for these examples were prepared in equipment substantially similar to that shown in FIG. A
[0092]
Example Fifteen ~ 16
In Examples 15 and 16, an ultraviolet lamp was positioned to cure the slurry on the production tool. In Example 15, the production tool was a gravure roll having an LP6 arrangement. In Example 16, the production tool was a gravure roll having a CC arrangement.
[0093]
Comparative example C and D
In Comparative Examples C and D, the UV lamp was positioned so that the slurry was cured after being removed from the production tool. Thus, there is a time lag between when the intermediate article is left on the production tool and when the adhesive cures or gels. This delay causes the adhesive to flow, changing the arrangement and shape of the composite. In Comparative Example C, the production tool had a CC sequence, and in Comparative Example D, the production tool had an LP6 sequence.
[0094]
The improvements in the coated abrasive article of the present invention when compared to conventional coated abrasive articles result from curing or gelling in the production tool. This improvement is more readily apparent from the photographs of FIGS. 6, 7, 15 and 16. 15 and 16 are of Comparative Example C, while FIGS. 6 and 7 are of Example 16. FIG. 11 shows the output of the surface profile test of the coated abrasive article of Comparative Example D.
[0095]
[Table 9]
[0096]
The most preferred coated abrasive products are those that have high cuts with low surface finish values. The abrasive article of the present invention meets this criterion.
[0097]
Example 17 ~ 20
The abrasive articles of these examples illustrate the curing of various adhesives. An abrasive article was prepared and tested in the same manner as in Example 1 except that a different adhesive was used. The weight ratio of the materials in the slurry was the same as in Example 1. The adhesive for Example 17 was TMDIMA2, the adhesive for Example 18 was BAM, the adhesive for Example 19 was AMP, and the adhesive for Example 20 was TATHEIC. The test results are shown in Table 9 below. Comparative Example A was Grade 600 wet or dry TRI-M-ITE A weight paper commercially available from Minnesota Mining and Manufacturing Company, St. Paul, Minnesota.
[0098]
[Table 10]
[0099]
Example 21 ~ 24
Except for using a different slurry, the coated abrasive articles of Examples 21 to 24 were produced in the same manner as in Example 16. In Example 21, a polishing slurry composed of fused alumina grains (100 parts) / TMDIMA2 (90 parts) / IBA (10 parts) / PH1 (2 parts) having an average particle size of 40 μm was used. In Example 22, an average of 40 μm was used. A polishing slurry consisting of fused alumina grains having a particle size of 200 parts / TMDIMA2 (90 parts) / IBA (10 parts) / PH1 (2 parts) was used. In Example 23, a fused alumina grain (200 parts) having an average particle size of 40 μm was used. Parts / AMP (90 parts) / IBA (10 parts) / PH1 (2 parts), and in Example 24, fused alumina grains (200 parts) / TATHEIC (90 parts) having an average particle size of 40 μm Parts) / IBA (10 parts) / PH1 (2 parts). Comparative Example E was a grade 400 wet or dry TRI-M-ITE A-weight paper commercially available from Minnesota Mining and Manufacturing Company, St. Paul, Minnesota.
[0100]
Lap test
The abrasive article was a 35.6 cm diameter disc and tested on an RH Strasberg 6AX wrapping machine. The workpiece was made into a circular shape with a diameter of 7.5 cm and three 1018 steel rods with a diameter of 1.2 cm set in a holder. Lapping was performed without water and the normal (vertical) load on the workpiece was 1 kg. The workpiece drive spindle was offset to 7.6 cm. The workpiece drive spindle rotation from the center of the lap was 63.5 rpm. The wrap was rotated at 65 rpm. The coated abrasive disc was mounted on an abrasive holder with double coated tape. The test was stopped at 5, 15, 30, and 60 minute intervals to determine the cumulative cut. The test results are shown in Table 10 below.
[0101]
[Table 11]
[0102]
By selecting an appropriate arrangement and shape of the composite, the cutting speed can be maximized, the scratch depth can be minimized, and the uniformity of the scratch pattern can be maximized.
[0103]
The coated abrasive article of the present invention is not as heavy as the coated abrasive article of Comparative Example E. The uniform arrangement and shape of the composite of the coated abrasive article of the present invention contributes to its performance.
[0104]
In order to provide guidance in the area of manufacturing manufacturing tools for preparing coated abrasive articles of the present invention, those providing the following dimensions for coated abrasive articles are comprehensively illustrated in FIGS. 17-17. The dimensions, ie, inches or degrees of arc, are shown in Table 11 below.
[0105]
[Table 12]
[0106]
Various modifications and alterations of this invention will be apparent to those skilled in the art without departing from the scope and spirit of this invention, and it is to be understood that this invention is limited to the illustrative embodiments illustrated herein. is not.
[Brief description of the drawings]
FIG. 1 is a cross-sectional side view of an abrasive article of the present invention.
FIG. 2 is a schematic view of an apparatus for producing the abrasive article of the present invention.
FIG. 3 is an external view of an abrasive article of the present invention.
FIG. 4 is a scanning electron micrograph taken at 30 × magnification of the top surface of an abrasive article having an array of linear grooves.
FIG. 5 is a scanning electron micrograph taken at 100 × magnification of a lateral side of a coated abrasive article having a linear groove arrangement.
FIG. 6 is a scanning electron micrograph of a top view of an abrasive article having a pyramid-shaped array at a magnification of 20 times.
FIG. 7 is a scanning electron micrograph taken at 100 × magnification of a side surface of an abrasive article having a pyramid-shaped array.
FIG. 8 is a scanning electron micrograph (upper surface) of an abrasive article having a saw blade array at a magnification of 30 times.
FIG. 9 is a scanning electron micrograph (side view) of an abrasive article having a saw blade array at a magnification of 30 times.
FIG. 10 is a graph from a surface profile test of the abrasive article of the present invention.
FIG. 11 is a graph from a surface profile test of an abrasive article made according to the prior art.
FIG. 12 is a schematic front view for an arrangement of linear grooves.
FIG. 13 is a schematic front view for an arrangement of linear grooves.
FIG. 14 is a schematic front view for an arrangement of linear grooves.
FIG. 15 is a top view of a scanning electron micrograph of a conventional abrasive article taken at 20 × magnification.
FIG. 16 is a top view of an electron micrograph of a conventional polishing article taken at 100 × magnification.
FIG. 17 is a schematic front view for arrangement of a specific pattern.
FIG. 18 is a schematic front view for arrangement of a specific pattern.
FIG. 19 is a schematic front view for arrangement of a specific pattern.
Claims (23)
(2)裏材料の片側の主要表面をスラリーが濡らすように製造用具の外側表面に裏材料を導入することにより、中間用品を形成する工程;
(3)該中間用品が製造用具の外側表面から分離する前にバインダーを少なくとも部分的に硬化またはゲル化させることにより、被覆研摩用品を形成する工程;および
(4)該被覆研摩用品を製造用具から除去する工程;
を包含する被覆研摩用品を作製する方法。(1) introducing a slurry containing a mixture of a binder and a plurality of abrasive grains onto a production tool;
(2) forming an intermediate article by introducing the backing material to the outer surface of the manufacturing tool such that the slurry wets one major surface of the backing material;
(3) forming a coated abrasive article by at least partially curing or gelling the binder before the intermediate article separates from the outer surface of the production tool; and (4) producing the coated abrasive article. Removing from;
A method for producing a coated abrasive article comprising:
(2)外側表面を有する製造用具であって該製造用具の外側表面が特定のパターンを有するものに該中間用品を導入する工程;
(3)中間用品が製造用具の外側表面から分離する前に少なくとも部分的にバインダーを硬化またはゲル化させることにより、被覆研磨用品を形成する工程;および
(4)該製造用具から被覆研摩用品を除去する工程;
を包含する被覆研摩用品を作製する方法。(1) forming an intermediate article by introducing a slurry comprising a mixture of a binder and a plurality of abrasive grains onto the backing material such that the slurry wets the front side of the backing material;
(2) introducing the intermediate article into a manufacturing tool having an outer surface, wherein the outer surface of the manufacturing tool has a specific pattern;
(3) forming a coated abrasive article by at least partially curing or gelling the binder before the intermediate article separates from the outer surface of the production tool; and (4) removing the coated abrasive article from the production tool. Removing;
A method for producing a coated abrasive article comprising:
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
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US07651660 US5152917B1 (en) | 1991-02-06 | 1991-02-06 | Structured abrasive article |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
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JP50455692A Division JP3459246B2 (en) | 1991-02-06 | 1992-01-07 | Method of making coated abrasive article |
Publications (1)
Publication Number | Publication Date |
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JP2004001221A true JP2004001221A (en) | 2004-01-08 |
Family
ID=24613696
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
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JP50455692A Expired - Fee Related JP3459246B2 (en) | 1991-02-06 | 1992-01-07 | Method of making coated abrasive article |
JP2003173709A Pending JP2004001221A (en) | 1991-02-06 | 2003-06-18 | Polishing supply with structure |
Family Applications Before (1)
Application Number | Title | Priority Date | Filing Date |
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JP50455692A Expired - Fee Related JP3459246B2 (en) | 1991-02-06 | 1992-01-07 | Method of making coated abrasive article |
Country Status (17)
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US (2) | US5152917B1 (en) |
EP (1) | EP0570457B1 (en) |
JP (2) | JP3459246B2 (en) |
CN (3) | CN1230281C (en) |
AT (1) | ATE137154T1 (en) |
AU (1) | AU661473B2 (en) |
BR (1) | BR9205596A (en) |
CA (1) | CA2100059C (en) |
CZ (1) | CZ158193A3 (en) |
DE (1) | DE69210221T2 (en) |
ES (1) | ES2086731T3 (en) |
HK (2) | HK1006688A1 (en) |
HU (1) | HUT68648A (en) |
MX (1) | MX9200306A (en) |
RU (1) | RU2106238C1 (en) |
SG (1) | SG73390A1 (en) |
WO (1) | WO1992013680A1 (en) |
Cited By (2)
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1992
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- 1992-01-07 DE DE69210221T patent/DE69210221T2/en not_active Expired - Lifetime
- 1992-01-07 CZ CS931581A patent/CZ158193A3/en unknown
- 1992-01-07 AT AT92904602T patent/ATE137154T1/en not_active IP Right Cessation
- 1992-01-07 BR BR9205596A patent/BR9205596A/en not_active IP Right Cessation
- 1992-01-07 AU AU12403/92A patent/AU661473B2/en not_active Ceased
- 1992-01-07 CA CA002100059A patent/CA2100059C/en not_active Expired - Lifetime
- 1992-01-07 ES ES92904602T patent/ES2086731T3/en not_active Expired - Lifetime
- 1992-01-07 SG SG1996005019A patent/SG73390A1/en unknown
- 1992-01-07 HU HU9302029A patent/HUT68648A/en unknown
- 1992-01-07 JP JP50455692A patent/JP3459246B2/en not_active Expired - Fee Related
- 1992-01-07 RU RU93054180A patent/RU2106238C1/en not_active IP Right Cessation
- 1992-01-07 WO PCT/US1992/000305 patent/WO1992013680A1/en not_active Application Discontinuation
- 1992-01-24 MX MX9200306A patent/MX9200306A/en unknown
- 1992-02-02 CN CNB001009923A patent/CN1230281C/en not_active Expired - Lifetime
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1993
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1998
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-
2000
- 2000-01-17 CN CN00100992A patent/CN1269277A/en active Granted
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2001
- 2001-04-10 HK HK01102518A patent/HK1032021A1/en not_active IP Right Cessation
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2003
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Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
KR101085771B1 (en) * | 2003-09-23 | 2011-11-21 | 쓰리엠 이노베이티브 프로퍼티즈 컴파니 | Structured abrasive with parabolic sides |
WO2017126815A1 (en) * | 2016-01-22 | 2017-07-27 | 주식회사 썬텍인더스트리 | Grinding article having protrusions and recesses, and method of manufacturing same |
Also Published As
Publication number | Publication date |
---|---|
CN1230281C (en) | 2005-12-07 |
EP0570457A1 (en) | 1993-11-24 |
US5152917A (en) | 1992-10-06 |
ES2086731T3 (en) | 1996-07-01 |
BR9205596A (en) | 1994-04-26 |
MX9200306A (en) | 1992-09-01 |
DE69210221D1 (en) | 1996-05-30 |
ATE137154T1 (en) | 1996-05-15 |
CN1066087C (en) | 2001-05-23 |
AU661473B2 (en) | 1995-07-27 |
RU2106238C1 (en) | 1998-03-10 |
CZ158193A3 (en) | 1994-02-16 |
CN1064830A (en) | 1992-09-30 |
HUT68648A (en) | 1995-07-28 |
CN1269277A (en) | 2000-10-11 |
CA2100059C (en) | 2002-06-25 |
CA2100059A1 (en) | 1992-08-07 |
AU1240392A (en) | 1992-09-07 |
DE69210221T2 (en) | 1997-01-09 |
JP3459246B2 (en) | 2003-10-20 |
JPH06505200A (en) | 1994-06-16 |
US5304223A (en) | 1994-04-19 |
HK1006688A1 (en) | 1999-03-12 |
WO1992013680A1 (en) | 1992-08-20 |
HK1032021A1 (en) | 2001-07-06 |
US5152917B1 (en) | 1998-01-13 |
SG73390A1 (en) | 2000-06-20 |
EP0570457B1 (en) | 1996-04-24 |
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